Rigid wall assembly for emergency isolation and treatment shelter (EITS)

ABSTRACT

An Emergency Isolation and Treatment Shelter (EITS) rigid wall system is modular and includes two support columns and a rigid wall assembly therebetween. The rigid wall assembly includes a lower panel extrusion, a lower panel, a center wall extrusion, and an upper panel. The lower panel and the upper panel are of equivalent dimensions and are interchangeable.

BACKGROUND OF THE INVENTION

The present invention relates to a temporary emergency shelter, and moreparticularly to a wall system therefor.

Most structures are built from traditional materials and features whichare inappropriate for non-traditional construction applications speed ofassembly is essential. One situation where common methods and materialsare particularly inappropriate is emergency/natural disaster situationsor military operations in remote locations. In such situations, it isrequired that the materials used to construct a temporary building belight weight such that they are readily transported. Other requirementsinclude low cost, ease of assembly, and minimization of the toolsrequired for assembly.

Various prefabricated, temporary and modular building systems currentlyexist. Each has various tradeoffs including transportability,construction time and resistance to the elements. Typically, the morepermanent the structure the less transportable the structure becomes andthe greater the terrain preparation is required upon which the temporarystructure is to be built.

One complicating factor regarding the construction of a temporarystructure is that the terrain where the structure is to be located maynot be suitable for construction of conventional prefabricatedstructures. Oftentimes, the site where the structure is to be locatedincludes undesirable terrain features such as undulated terrain andother undesirable environmental conditions such as sandy, muddy orflooded terrain which complications construction of relatively rigid andpermanent temporary structures. Such complications are particularlyacute for emergency hospital-type structures which require sterilelocations and may need to be capable of overpressure to sustainoperation in nuclear biological and chemical (NBL) environments.

Accordingly, it is desirable to provide a modular, lightweight,easily-assembled, relatively rigid and permanent building structure anda method for assembly therefore which readily accommodates undesirableterrain features.

SUMMARY OF THE INVENTION

The Emergency Isolation and Treatment Shelter (EITS) rigid wall systemaccording to the present invention defines one or more structures on adeck system. The rigid wall system is modular in that each rigid wallassembly generally includes two support columns and a rigid wallassembly therebetween.

The rigid wall assembly generally includes a lower panel extrusion, alower panel, a center wall extrusion, and an upper panel. The lowerpanel and the upper panel are of a sandwich construction manufacturedwith an aluminum skin over a rigid urethane foam core to combine lightweight with high strength. The lower panel and the upper panel are ofequivalent dimensions and are interchangeable. Also, the upper panel mayinclude a window.

The lower panel extrusion is generally U-shaped in cross section with acentral tab. The center wall extrusion is generally I-shaped in crosssection. The wall assembly is readily assembled by mounting the lowerpanel extrusion to a long side of the lower panel, the center wallextrusion to the opposite side of the lower panel then the upper panelto the opposite side of the center wall extrusion. The lower panel andthe upper panel are interference or friction fit into the respectivelower panel extrusion and the center wall extrusion. It should beunderstood that other resilient seals may additionally be provided.

Once the deck system has been assembled, the rigid wall system islocated thereon to define one or more structures. Each support column ismounted to the deck system such that fasteners are located through deckplate apertures of the column deck plate, through a deck surface paneland threaded into deck attachment apertures of the deck attachment platein an adjustable leg assembly. The rigid wall assembly is then engagedwith one wall receipt slot of a support columns and the central tab ofthe lower panel extrusion is slid into the interface or gap betweenadjacent deck surface panels. Such an interface adds further rigidity tothe wall system as well as structurally locking each the rigid wallassembly to the deck system.

The present invention therefore provides a modular, lightweight,easily-assembled, relatively rigid and permanent building structure anda method for assembly therefore which readily accommodates undesirableterrain features.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of this invention will becomeapparent to those skilled in the art from the following detaileddescription of the currently preferred embodiment. The drawings thataccompany the detailed description can be briefly described as follows:

FIG. 1A is a perspective view of an exemplary EITS structure;

FIG. 1B is an exemplary multi-structure EITS system;

FIG. 2A is an exploded view of a deck unit module;

FIG. 2B is an exploded view of an adjustable leg assembly of the deckmodule unit;

FIG. 2C is a perspective view of a deck unit module illustrating theaccommodation of an uneven terrain surface;

FIG. 2D is a perspective view of a lower truss of the deck unit module;

FIG. 2E is a perspective view of an adjustable leg assembly in aretracted position;

FIG. 3 is a perspective view of a support column mounted to a multipleof deck unit modules;

FIG. 4A is an exploded view of a rigid wall assembly relative to thedeck system;

FIG. 4B is a side view of a support column;

FIG. 4C is a top view of the support column;

FIG. 4D is an expanded top view of a support column;

FIG. 4E is an exploded view of a rigid wall assembly;

FIG. 4F is a sectional view of a lower panel extrusion of the rigid wallassembly;

FIG. 4G is a sectional view of a center wall extrusion of the rigid wallassembly;

FIG. 4H is an exploded view of the rigid wall assembly prior to beingmounted to the support column;

FIG. 4I is an expanded perspective view of the rigid wall assembly priorto mounting to the deck system;

FIG. 5A is a perspective view of a roof support structure of a roofsystem;

FIG. 5B is a perspective view of a roof truss;

FIG. 5C is an exploded view of the roof truss attachable to another rooftrus to form a peaked roof;

FIG. 5D is an expanded face view of a purlin attachment plate;

FIG. 5E is a perspective view of a peak purlin;

FIG. 5F is a side view of the peak purlin;

FIG. 5G is a sectional view transverse to the length of the peak purlin;

FIG. 5H is a perspective view of an intermediate roof purlin;

FIG. 5I is a side view of the intermediate roof purlin;

FIG. 5J is a sectional view transverse to the length of the intermediatepurlin;

FIG. 5K is a side view of an end attachment bracket of a purlin endattachment bracket;

FIG. 5L is a perspective view of a purlin attachment stud;

FIG. 6A is an exploded view of a roof truss relative to the supportcolumns;

FIG. 6B is a perspective view of a wall cap soffit;

FIG. 6C is a sectional view through a longitudinal length of the wallcap soffit;

FIG. 6D is an exploded view of a wall cap soffit prior to assembly tothe rigid wall system;

FIG. 7A is a perspective view of a roof system with roof panels mounted;

FIG. 7B is a perspective view of a roof panel;

FIG. 7C is an end view of a roof panel illustrating a male and femaleattachment side thereof;

FIG. 7D is an assembled view of two roof panels;

FIG. 7E is an edge view of the roof panel attachment;

FIG. 8A is an exploded view of a roof cap system;

FIG. 8B is a perspective view of a roof cap;

FIG. 8C is a perspective view of a roof gable end soffit cap;

FIG. 8D is a perspective view of a roof gable end cap;

FIG. 8E is a perspective view of an intermediate roof cap;

FIG. 8F is a perspective view of a roof cap end;

FIG. 9A is an internal perspective view of a transport channel a roofsystem;

FIG. 9B is an internal perspective view of a transport channel a roofsystem; and

FIG. 9C is a perspective view of a HVAC conduit within the roof system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1A illustrates a general perspective view of an Emergency Isolationand Treatment Shelter (EITS) 10. The EITS generally includes a decksystem 12, a rigid wall system 14 and a roof system 16. The EITS 10 is arigid-walled, modular, container transportable facility that is rapidlydeployable in a variety of situations. The EITS 10 can be erected andfully functioning within days offering shelter, electrical services,heating/cooling, and bathroom facilities. Assembled quicker thanpre-cast or stick built structures, the EITS 10 can be erected for shortor long term usage upon a variety of undesirable terrain features.Although a simplified structure is disclosed in the illustratedembodiment, it should be understood that a multitude of variousstructures may be combined as modules to provide significant facilities(FIG. 1B) which may be utilized for various purposes.

Referring to FIG. 2A, the deck system 12 is constructed from a multipleof deck unit modules 18. Each deck unit module 18 includes fouradjustable leg assemblies 20 attachable together by a lower truss 22L,22S between each leg assembly 20 so as to support a deck surface panel24. The deck unit modules 18 may be attached together to form a decksystem 12 of any desired shape and size. Preferably, each surface panel24 is a rectilinear four feet by eight feet panel, but deck surfacepanels 24 of any size may be usable with the present invention. The decksurface panel 24 is preferably of a laminated sandwich construction toprovide a rigid structure which is supported by the trusses 22L, 22S.

Preferably, the size of the deck unit module 18 defines the modularityof the EITS 10. That is, each deck unit module 18 is a building block bywhich the other components such as walls are related. It should befurther understood that the deck system 12 may be utilized for variouspurposes other than as a component of the EITS 10 such as a stage orbridge system.

Referring to FIG. 2B, each leg assembly 20 includes a primary leg 26, anintermediate leg 28 and a screw foot 30 each in telescopic relationship.Each leg assembly 20 may be telescoped independently to provide a leveldeck surface 24 irrespective of the underlying terrain (FIG. 2C).

The primary leg 26 is of generally tubular construction with an uppertruss attachment flange 32 and a lower truss attachment flange 34. Theupper truss attachment flange 32 and the lower truss attachment flange34 preferably each include eight truss attachment apertures 35 such thatthe lower truss 22L, 22S may be mounted at forty-five (45) degreeincrements about any leg assembly 20. Each lower truss 22L, 22S includesan upper and lower attachment hook 23 (FIGS. 2A and 2D) adjacent eachcorner thereof to selectively engage one of the truss attachmentapertures 35 of the upper truss attachment flange 32 and the lower trussattachment flange 34.

The uppermost end segment of the primary leg 26 includes a deckattachment plate 40. The deck attachment plate 40 preferably includesfour deck attachment apertures 42 such that four deck surfaces 24 mayinterface upon a single deck attachment plate 40 with fasteners f (FIG.3).

Coarse height adjustment is provided between the primary leg 26, and theintermediate leg 28 through a pinned interface 36, while a finer heightadjustment is provided by a threaded interface 38 between theintermediate leg 28 and the screw foot 30. The primary leg 26 includes aprimary pin aperture 44 while the intermediate leg 28 includes amultiple of intermediate pin apertures 46. Preferably, the intermediatepin apertures are elongated to facilitate adjustment and assembly (bestseen in FIG. 2E). A pin 47 is received through the primary pin aperture44 to engage one of multiple of intermediate pin apertures 46 to providethe coarse adjustment. The threaded interface 38 between theintermediate leg 28 and the screw foot 30 is preferably an ACME threadin which a wing nut 48 is selectively rotated to adjust the length ofthe screw foot 30 relative the intermediate leg 28.

The deck system 12 may be assembled in various arrangements such thatthe intersection of up to four deck unit modules 18 are attachedtogether with each leg assembly 20. That is, each leg assembly 20 mayconnect up to four deck unit modules 18—one for each deck attachmentaperture 42.

Referring to FIG. 4A, each deck unit module 18 of the deck system 12 isfurther connected to adjacent deck unit module(s) 18 by the rigid wallsystem 14. The rigid wall system 14 is also modular in that each wallmodule generally includes two support columns 50 and a rigid wallassembly 64 therebetween.

Referring to FIG. 4B, the support column 50 is a tubular generallyrectilinear member in cross-section having a center opening 55 and awall receipt slot 56A-56D on each side thereof (FIG. 4C). Each wallreceipt slot 56A-56D preferably includes a seal slot 58 therein toreceive seal 60 to assure a waterproof seal (FIG. 4D). Intermediate eachwall receipt slot 56A-56D is an auxiliary area 62A-62D which permitsrunning of conduits for electrical wiring, plumbing conduits as well asjunction boxes, switch boxes or the like.

Each wall receipt slot 56A-56D is generally defined along each side ofthe support column 50 with the auxiliary area 62A-62D located at eachcorner to define a frustro-triangular cross-sectional area having theapex thereof is located at the corner of the support column. The supportcolumn 50 includes a column deck plate 52 having a set of deck plateapertures 52A (FIG. 4C) which corresponds with the deck attachmentapertures 42 of the deck attachment plate 40 (FIG. 2B).

Referring to FIG. 4E, each the rigid wall assembly 64 generally includesa lower panel extrusion 66, a lower panel 68, a center wall extrusion70, and an upper panel 72. The lower panel 68 and the upper panel 72 arepreferably of a sandwich construction manufactured with an aluminum skinover a rigid urethane foam core to combine light weight with highstrength. The lower panel 68 and the upper panel 72 are preferably ofequivalent dimensions and are interchangeable. It should be understoodthat although a solid lower panel 68 and an upper panel 72 with a window74 are disclosed in the illustrated embodiment, various panel typesincluding window and non window panels are usable with the presentinvention. In addition, and prefabricated assemblies such as single doorassemblies 64S (FIG. 1B), double door assemblies 64D (FIG. 1B),multi-door assemblies 64M (FIG. 1) as well as other prefabricatedassemblies may also be installed between two support columns 50 toprovide various structure features.

The lower panel extrusion 66 is generally U-shaped in cross section witha central tab 74 (FIG. 4F). The center wall extrusion 70 is generallyI-shaped in cross section (FIG. 4G). The wall assembly 64 is readilyassembled by mounting the lower panel extrusion 66 to a long side of thelower panel 68, the center wall extrusion 70 to the opposite side of thelower panel 68 then the upper panel 72 to the opposite side of thecenter wall extrusion 70. The lower panel 68 and the upper panel 72 areinterference or friction fit into the respective lower panel extrusion66 and the center wall extrusion 70. It should be understood that otherresilient seals may additionally be provided.

Once the deck system 12 has been assembled, the rigid wall system 14 islocated thereon to define one or more structures S (FIGS. 1A and 1B).Each support column 50 is mounted to the deck system 12 such thatfasteners f are located through the deck plate apertures 52A of thecolumn deck plate 52, through the deck surface panel 24 and threadedinto the deck attachment apertures 42 of the deck attachment plate 40 inthe leg assembly 20 (FIG. 3). The rigid wall assembly 64 is then engagedwith one of the wall receipt slots 56A-56D (FIG. 4H) and central tab 74of the lower panel extrusion 66 is slid into the interface or gapbetween adjacent deck surface panels 24 (FIG. 41). Such an interfaceadds further rigidity to the wall system 14 as well as structurallylocking each the rigid wall assembly 64 to the deck system 12.

The next support columns 50 is then mounted to the deck system 12 andthe rigid wall assembly 64 as described above. Such modular assembly isthen repeated to assemble the rigid wall system 14 upon the deck system12 to define the outer perimeter of the one or more structures S (FIG.1B). Such assembly is relatively rapid due in part to the light weightof the components, their interchangeability and the grid-like patternformed by the interface between adjacent deck surface panels 24 of thedeck system 12.

Referring to FIG. 5A, once the rigid wall system 14 has been assembled,the roof system 16 is located thereon to finish the exterior of thestructures S (FIG. 1A and 1B). The roof system 16 generally includes aroof support structure 78 including a multiple of identical componentparts which are assembled together in a modular manner. The roof supportstructure 80 includes at least one of a roof truss 82, a peak purlin 84,a roof intermediate purlin 86 and a wall cap soffit 88.

Referring to FIG. 5B, the roof truss 82 is a generally triangular memberhaving roof truss end tabs 90A, 90B and a purlin attachment plate 94A,94B (also illustrated in FIG. 5D). The roof truss 82 is preferably sizedto fit within a shipping container and is approximately 16 feet inlength, however, trusses of other sizes are also usable with the presentinvention. Preferably, two roof trusses 82 are attached together (FIG.5C) to form a peaked roof.

The roof center attachment plate 92 and the purlin attachment plates94A, 94B include a multitude of key hole apertures 96. Each peak purlin84 (also illustrated in FIGS. 5E-5G) and roof intermediate purlin 86(also illustrated in FIGS. 5H-5J) include end attachment brackets 98which are engageable with the multitude of key hole apertures 96 of therespective purlin attachment plates 94A, 94B (FIG. 5A). Preferably, theend attachment brackets 98 are located at the end of, and on opposedsides of, the peak purlin 84 and roof intermediate purlin 86 such thatadjacent peak purlins 84 and roof intermediate purlins 86 sandwichvertical truss support members therebetween. The end attachment brackets98 are mounted to the purlin attachment plates 94A, 94B with anattachment stud 95 which engages the keyhole apertures 96 and a fastener(FIGS. 5K and 5L).

Referring to FIG. 6A, to assemble the roof support structure 78 to therigid wall system 14, the roof truss end tabs 90A, 90B are located intothe center opening 55 of two support columns 50 and are preferablyfastened in place with bolts or the like. Each roof truss 82 isattachable to an adjacent roof truss 82 at adjacent roof centerattachment plates 92 (FIG. 5A). That is, the roof truss end tabs 90A,90B are located into the center opening 55 of the support columns 50 andtwo adjacent roof trusses 82 are locked together at the roof centerattachment plates 92. The wall cap soffit 88 (FIGS. 6B and 6C) is thenmounted to the top of the rigid wall system 14 transverse to the rooftruss 82 along the length thereof such that each wall cap soffit tab 100is fitted within the center opening 55 of the support columns 50 (FIG.6D). Notably, the end wall cap soffit tab 100 is half the width of thecenter wall cap soffit tab 100 which completely fills the center opening55 of the support column 50 as the end wall cap soffit tabs 100 willinterface with other tabs such as those of the roof truss 82 or of anadjacent wall cap soffit 88. Once the roof support structure 80 isassembled to the rigid wall system 14, a multitude of roof panels 102are locate thereon (FIG. 7A).

Referring to FIG. 7A, the roof panels 102 are located between the peakpurlin 84 and the wall cap soffit 88. The roof panels 102 are retainedbetween a wall cap soffit edge 88E of the wall cap soffit 88 (FIG. 6E)and a raised center member 84E of the peak purlin 84 (FIG. 5G) andinterface with adjacent roof panels 102 at an overlapping roof panelinterface 104. That is, each roof panel 102 includes a male raised edge104 which engages within a female raised edge 106. The raisedoverlapping roof panel interface 104 covers a stepped interface 108 witha seal member 110 which slips into a slot 112 on an opposite side of anadjacent roof panel 102. The adjacent roof panels 102 essentially justslide into engagement with each other (FIG. 7D) to provide a watertightyet readily assembled interface. That is, each roof panel 102 isidentical with a first edge 102A and a second edge 102B. The first edge102A of one roof panel 102 engages a second edge 102B of an adjacentroof panel 102. The roof panels 102 are preferably attached to the wallcap soffit 88 with a multitude of roof panel clips 105—preferably threeper roof panel 102 which engage an edge of the wall cap soffit 88E (FIG.6C).

Referring to FIG. 8A, once the multitude of roof panels 102 are locatedon the roof support structure 78, a roof cap system 114 is mounted overthe edge interfaces of the roof panels 102 and the roof supportstructure 78. A multitude of ridge caps 116 (FIG. 8B) are located alongthe peak purlin 84 and fastened in place through screws or the likewhich engage the top center slot of the peak purlin (FIG. 5G). Trusssheeting 118, 120 is then fastened to the exposed side of each externalroof truss 82. Preferably, the truss sheeting 118, 120 is pre-attachedto the exposed side of the trusses with rivets or the like prior toshipment to further streamline on-site assembly. A multitude of roofgable end soffit caps 122A-122C (FIGS. 8C and 8D) are then locate overthe interface between the roof panel 102 which abuts the end roof truss82 and fastened thereto. The roof gable end soffit caps 122A-122C arepreferably attached to the truss sheeting 118, 120 on the side of theroof trusses 82 to minimize attachments through the upper surfaces.Finally, ridge joint caps 124 (FIG. 8E) are located over the interfacebetween adjacent ridge caps 116 and a roof cap end 126 (FIG. 8F) islocated at the apex intersection to cover the interface between theridge caps 116 and the roof gable end soffit caps 122C. A watertightsystem is thereby rapidly assembled.

Referring to FIG. 9A, an internal view of the roof system 16 illustratesa transport channel 130 located along the length of the wall cap soffit88 and along each side of the peak purlin 84 (FIG. 9B). The transportchannel 130 provides support and storage area for the running of wires,water supply conduits, and the like to provide an unencumbered floorarea. The wires, water supply conduits, and the like are simply locatedwithin the transport channel 130 then run down the auxiliary area62A-62D within the support columns 50 for communication to the desiredlocation. For example only, wires may be run from light fixtures L alongthe transport channel 130, down the auxiliary area 62A-62D within thesupport column 50 and to a junction box or switch box. Wiring andplumbing is therefore readily installed within the structure.Environmental conditioning transport conduits such as HVAC tubularconduits C may likewise be run along the transport channel 130 as wellas mounted directly to the truss beams 82 (FIG. 9C).

It should be understood that relative positional terms such as“forward,” “aft,” “upper,” “lower,”“above,” “below,” and the like arewith reference to the normal operational attitude of the vehicle andshould not be considered otherwise limiting.

It should be understood that although a particular component arrangementis disclosed in the illustrated embodiment, other arrangements willbenefit from the instant invention.

Although particular step sequences are shown, described, and claimed, itshould be understood that steps may be performed in any order, separatedor combined unless otherwise indicated and will still benefit from thepresent invention.

The foregoing description is exemplary rather than defined by thelimitations within. Many modifications and variations of the presentinvention are possible in light of the above teachings. The preferredembodiments of this invention have been disclosed, however, one ofordinary skill in the art would recognize that certain modificationswould come within the scope of this invention. It is, therefore, to beunderstood that within the scope of the appended claims, the inventionmay be practiced otherwise than as specifically described. For thatreason the following claims should be studied to determine the truescope and content of this invention.

1. A rigid wall assembly for a modular structure comprising: an upper panel; a lower panel; a center wall extrusion mounted to said upper panel and said lower panel; and a lower panel extrusion mounted to said lower panel.
 2. The assembly as recited in claim 1, wherein said center wall extrusion is generally I-shaped in cross-section.
 3. The assembly as recited in claim 1, wherein said lower panel extrusion is generally U-shaped in cross section with a central tab.
 4. The assembly as recited in claim 1, wherein said upper panel and said lower panel are manufactured as a sandwich construction.
 5. The assembly as recited in claim 4, wherein said sandwich construction includes an aluminum skin over a rigid urethane foam core.
 6. The assembly as recited in claim 1, wherein said upper panel includes a window.
 7. The assembly as recited in claim 1, wherein said center wall extrusion is mounted to said upper panel and said lower panel through a friction fit.
 8. The assembly as recited in claim 1, wherein said a lower panel extrusion is mounted to said lower panel through a friction fit.
 11. A shelter system comprising: a deck system having a multitude of deck unit modules; and a rigid wall panel assembly having a lower panel extrusion with a tab which fits between two of said multitude of deck unit modules.
 12. The system as recited in claim 11, further comprising a shelter mounted to said deck system, said rigid wall panel forming a section of said shelter.
 13. The system as recited in claim 11, wherein said tab is located between two deck surfaces of two of said multiple of deck unit modules.
 14. The system as recited in claim 11, further comprising two support columns each mounted at an intersection of at least two of said multiple of deck unit modules, said rigid wall panel assembly mounted between said two support columns.
 15. The system as recited in claim 14, wherein each of said two support column is mounted at an intersection of four deck unit modules.
 16. The system as recited in claim 15, wherein each of said two support column is mounted to a respective adjustable leg assembly. 